Mat and support structure

The present application is the national stage of International (PCT) Patent Application No. PCT/US2023/030525, filed internationally on Aug. 18, 2023, and claims the benefit of and priority to U.S. provisional application No. 63/399,176, filed on Aug. 18, 2022, the disclosures of each of which are incorporated by reference as if set forth in their entirety herein.

Embodiments described herein generally relate to mats and, more particularly but not exclusively, to exercise mats and related components.

Exercise cushions or mats have become a common piece of equipment for a variety of exercises. These exercises may include, but are not limited to Yoga, Pilates, stretching, martial arts, circuit training, Tai Chi, high-intensity interval training (HIIT), or the like.

Existing exercise cushions or mats are typically formed as a single piece of material, which does not offer much structural support or stability for the user or the mat. Additionally, these existing, single-piece cushions or mats generally do not provide the user with an exciting user experience.

A need exists, therefore, for improved mats and methods of manufacturing the same.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

According to one aspect, embodiments relate to a mat. The mat includes a first mat portion; and at least one support structure including a first attachment portion configured to operably connect with the first mat portion, a first side to support a user, a second side opposite the first side and configured to be in operable contact with a surface separate from the mat, wherein the second side includes one or more portions that define at least one groove to enable the support structure to be in a rolled configuration with the first mat portion.

In some embodiments, the first attachment portion includes an attachment surface to operably connect the first mat portion.

In some embodiments, the first side includes a plurality of ridges to support the user. In some embodiments, the first side is compressible during support of the user, and the second side provides structural support during support of the user.

In some embodiments, the first side includes a smooth portion to support the user.

In some embodiments, the surface is a floor portion.

In some embodiments, the mat further includes a hinged portion between the attachment portion and at least one of the first side or the second side to enable the support structure to be in the rolled configuration with the mat portion.

In some embodiments, the at least one support structure is formed from at least one of thermoplastic elastomer, thermoplastic polyurethane, polyurethane, silicon, urethane, rubber, natural rubber, or cork.

In some embodiments, the at least one support structure and the first mat portion are operably connected via at least one of stitching, an adhesive, hook and loop fasteners, a mechanical attachment mechanism, magnets, or rivets.

In some embodiments, the first side of the support structure is shaped as an arch.

In some embodiments, the at least one support structure further comprises at least one gripping element configured with the second side to removably secure the support structure to the surface.

In some embodiments, the second side includes a plurality of portions that define a plurality of grooves between each of the portions to enable the support structure to be in the rolled configuration with the mat portion.

In some embodiments, the mat further includes a second mat portion, wherein the at least one support structure further includes a second attachment portion configured to operably connect with the second mat portion.

In some embodiments, the mat further includes at least a second support structure including an attachment portion configured to operably connect with the first mat portion, a first side to support the user, and a second side opposite the first side and configured to be in operable contact with the surface, wherein the second side includes one or more portions that define at least one groove to enable the second support structure to be in a rolled configuration with the first mat portion and the first support structure.

According to another aspect, embodiments relate to a support structure for a user. The support structure includes an attachment portion configured to operably connect with a mat portion, a first side comprising an arched surface to support the user, and a second side opposite the first portion and including one or more portions that define at least one groove to enable the support structure to be in a rolled configuration.

In some embodiments, the attachment portion includes an attachment surface to operably connect with the mat portion.

In some embodiments, the support structure is formed from at least one of thermoplastic elastomer, thermoplastic polyurethane, polyurethane, silicon, urethane, rubber, natural rubber, or cork.

In some embodiments, the support structure further includes a hinged portion to create a fold point between the attachment portion and the first side or between the attachment portion and the second side.

In some embodiments, the mat further includes a second attachment portion to operably connect the support structure with a second mat portion.

In some embodiments, the mat further includes at least one gripping element configured with the second side to removably secure the support structure to a floor portion.

Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art.

Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein.

As discussed above, existing exercise mats are typically formed from a single piece of flat material. Even though these cushions may vary in thickness, material, texture, etc., they generally do not provide an exciting user experience. Additionally, and as stated previously, existing single-piece mats do not provide much support or stability for the user. For example, the support provided by a mat may be limited by the material and thickness of the mat, and may further diminish after repeated use.

Some existing mats include supports or cushions that are strategically positioned on the mat. These cushions may require a separate cover portion to receive or otherwise hold the cushions, or the cushions may be integrated with the mat. However, positioning the supports on the mat increases the volumetric footprint of the mat, and makes it difficult to fold or otherwise roll the mat for transport or storage.

The embodiments described herein provide novel mats and related components, as well as methods for manufacturing the same. The mats in accordance with the described embodiments include one or more support structures that help support or otherwise stabilize a user. The support structure(s) may be operably positioned with respect to one or more mat portions so that a user may contact the support structures (e.g., with their hands, fingers, palms, elbows, back, neck, knees, feet, etc.) during use.

The support structure(s) may include one or more grooved or ridge portions. These portions not only provide comfort, stability, support, and an improved tactile experience for the user, but also allow a user to maneuver the mat into a rolled configuration.

In the context of the present application, “rolled configuration” may refer to a configuration in which the support structure(s) has a radius of curvature that increases at approximately the same rate as that of the mat portion(s). Additionally, the height, thickness, compressibility, etc., of the support structure(s) should be such that the mat can be rolled similarly to how a mat made of a single, uniform material would be rolled.

This is in contrast to existing mats, such as those with cushions directly attached to or integrated onto the mat. Although a user may technically fold or roll these mats to some degree, these cushions would prevent these existing mats from being rolled as neatly and compact as if the existing mat was made from and included only a single, uniform material.

Although the present application largely discusses mats in the context of exercise equipment, the features of the described embodiments may be implemented in other applications. For example, and without limitation, other applications in which a user wants comfort or support while in various positions may benefit from the described embodiments. These may include, but are not limited to, applications in plumbing, carpentry, vehicle maintenance or repair, appliance repair, construction, acupressure massage, reflexology, meditation, activities associated with the practice of religion, physical therapy, podiatry, or the like. The above list is merely exemplary, and the features of the described embodiments may be implemented in other applications in addition to or in lieu of those listed above and described herein.

illustrates a top view of a matin accordance with one embodiment. The matmay include a first mat portion, a second mat portion, and support structures,, and. In this embodiment, the matmay be intended for use as part of a floor exercise such as yoga, stretching, or Pilates. Accordingly, the support structures-may be sized and positioned such that a user would contact the support structures-while in positions or during movements common in the applicable activity.

The first mat portionmay be formed from an any suitable material. For example, and without limitation, the first mat portionmay be formed from a thermoplastic elastomer (for simplicity, “TPE”), polyurethane (“PU”), thermoplastic polyurethane (“TPU”), natural rubber, rubber, foam, vinyl, polyester synthetic materials, PVC, thermoplastic elastomers, or some combination thereof. The second mat portionmay be similar to the first mat portionin this regard.

illustrates a side view of the support structureofin accordance with one embodiment. The support structuremay include a first sideto support a user, and a second sidethat is opposite the first side. The second sideis configured to be in operable contact with a surface that is separate from the mat, such as the floor or ground.

The support structuremay be formed from one or more different types of materials. These may include, but are not limited to, silicon, rubber, natural rubber, TPE, PU, TPU, cork, or any other suitable material available now or invented hereafter. The support structuremay be formed from composites or combinations of various materials, including those listed above.

The first sidemay have a tapered or raised shape, and may include a plurality of ridgesfor receiving a portion of the user's body. For example, during use it may be common for a user to place their fingers, neck, hands, or feet on the ridgesor within the space between ridges. These ridgesmay, among other benefits, also provide anti-slip functionality for a user during use. The ridgesmay therefore offer advantages over a flat mat in preventing slippage such as if a user contacts the ridgesat an inclined angle, such as with their arms and hands while in a “downward dog” position, which is common in Yoga.

The height-to-width ratio of the ridgesmay be chosen such that they feel compressible during use to provide comfort and a tactile experience for the user. The ridgesalso allow for less material to be used, which results in material savings, reduced costs, and reduced weight.

The size or number of the ridgesmay vary. In some embodiments, the size or number of the ridgesmay be based on the size of the user. In some embodiments, the size or number of the ridgesmay be based on the expected purpose(s) of the ridgesor the matin general. For example, it may be preferable to have a certain number of ridgesor to have ridgesof a certain size for one exercise, but preferable to have a different number of ridgesor have ridgesof a different size for another exercise.

Similarly, the size of the support structuremay vary. For example, wider support structuresmay have more ridgesthan smaller support structures.

The second sidemay include a plurality of grooves, the space between which may contact a surface that is separate from the mat. For example, the space or structure between the groovesmay contact the floor or other type of ground surface.

The groovesmay be defined by a series of raised portions and a series of depressed portions, wherein a depressed portion is between each pair of raised portions. As discussed below, the depressed portions in effect create the groovesor otherwise the negative space that may at least assist in allowing the support structure, and also the mat, to be maneuvered into a rolled configuration.

illustrates a sectionof the groovesofin accordance with one embodiment. The groovesmay include or otherwise be defined by a bottom portion, a top portion, and leg portions. During use, the bottom portionsmay contact the surface that is separate from the mat, such as the floor.

The portions that define the groovesofare illustrated as a trapezoid. However, the groovesmay be formed in any other appropriate shape or configuration. Similarly, the lengths or sizes of each of the bottom portion, top portion, the leg portions, and the angles formed therebetween may vary.

As seen in, these components also create groovesbetween the bottom portions, top portion, and leg portions. As discussed below, the defined groovesmay at least assist in allowing the support structure, and also the mat, to be maneuvered into a rolled configuration.

The support structuremay be formed from a flexible material such that it can be in a rolled configuration—independently or while connected with a mat portion. For example, leg portionsthat are opposite from each other across a negative space may move closer to each other or even contact each other while in a rolled configuration.

The size or number of the groovesmay vary. In some embodiments, the size or number of the groovesmay be based on the size of the user. In some embodiments, the size or number of the groovesmay be based on the expected purpose(s) of the support structureor the matin general. For example, larger bottom portionsand shorter leg portionsmay provide more structural support than smaller bottom portionsand longer leg portions.